Two Brothers Racing 005-630406V, 005-63407V Installation Instructions Manual

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Parts List

IMPORTANT - PLEASE READ CAREFULLY

Warranty

Two Brothers Racing products are intended for closed course competition purposes only, and therefore are sold “as is” without warranty. Two Brothers Racing specifically disclaims any warranties of merchantability or fitness for a particular purpose and disclaims all responsibility for consequential and incidental damages or any other losses arising from the use of these products or parts.

We recommend that this performance part be installed by a qualied

motorcycle technician. If you have any doubts as to your ability to install this performance part, please consult with your local motorcycle dealer. Read all

instructions rst before starting installation. Make sure the motorcycle and exhaust system are completely cool before starting the installation. Also, make sure the bike is secure on a centerstand or ideally a service lift during installation. Be sure to save all stock components for possible use later.

Installation Instructions

1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on a center stand or ideally a service lift.

2. Remove right side panel.

3. Remove upper mufer mounting bolts.

4. Remove S-bend mufer joint clamp.

5. Remove mufer assembly.

6. Assemble the V.A.L.E.™unit by slipping the S-bend tube through the X-lite™ring. Use the 4 (four) 6 x

14mm bolts and split lock washers to loosely attach

the X-Lite™ ring to mufer inlet.

7. Make sure that the supplied barrel clamp is at the

S-bend joint to the head pipe, slip S-bend tube of

V.A.L.E.™muffler assembly into head pipe. Use supplied 8 x 45mm socket head with washer through muffler mount and spacer (tapered side towards

mufer) then loosely attach to motorcycle using the

OEM nut.

Qty. Description Part Number

1 M-7 Mufer Canister 005-63-206M/207M 1 Stainless Steel S-Bend Tube 005-6301S 1 HARDWARE KIT 005-63-3 1 X-Ring Kit 005-7-2-3KIT 1 Barrel Clamp 005-27-59MSH 1 8mm Flat Washer 005-WF8 1 20mm Spacer 005-S-22-20 1 8x45mm Socket Head Cap Screw 005-SH845

1 Spark Arrestor (aluminum canister only) 005-106S

8. Making sure that the V.A.L.E.™assembly is oriented

correctly, securely tighten upper mufer mounting bolt.

9. Securely tighten the 4 (four) 6 x 14mm hex head bolts

of the V.A.L.E.™assembly.

10. Securely tighten the lower mufer barrel clamp.

11. Re-install right side panel.

12. Double check to make sure that all hardware is fully tightened.

13. Before you run the bike, clean off all ngerprints and

dirt, as any oily residue will etch the metal and become

somewhat permanent when the system gets hot. Run

the bike and enjoy. It is normal for some white smoke to appear the rst time you start the bike. This is packing/

manufacturing oil from inside the pipe burning off.

Check for gaps or leaks. If you nd a leak, a little high temperature silicon sealant should x it. After 50 to 100 miles, recheck all fasteners for tightness.

Mufer Inlet

X-Lite™ Ring

S-Bend Tube

V.A.L.E.™ Assembly Detail

Care & Cleaning

Keep system free of dirt and moisture. Store in a cool, dry place. Make sure vehicle is completely cool before maintenance.

Stainless Header System: Polished stainless steel pipes will turn a light golden hue after a few heat cycles, this is a normal characteristic of high quality stainless steel. Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth.

Titanium Header System: Polished titanium pipes will experience color shift ranging from deep blue/purple through amber after a few heat cycles. This is a normal characteristic of high quality titanium. Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth.

Polished Aluminum Canisters: Use an aluminum or mag wheel polish to restore the

bright nish to factory spec.

Brushed Aluminum Canisters: Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth.

Carbon Fiber Canisters: Clean using a mild water based spray cleaner. Always apply

cleaner or polish with a soft, clean cloth. Always make sure the berglass packing inside

is in good condition and not burned out, as exhaust heat inside an empty canister will deteriorate the carbon ber sleeve. TBR sells repack kits (Road - #005-10038, Offroad - #005-10038MX) that include everything you need to easily do it yourself.

Titanium Mufers: For cleaning use a mild water based spray cleaner. Always apply

cleaner or polish with a soft, clean cloth. Always make sure the berglass packing inside

is in good condition and not burned out, as exhaust heat inside an empty canister will

deteriorate the carbon ber sleeve.

TBR sells repack kits (Road - #005-10038, Offroad - #005-10038MX) that include everything you need to easily do it yourself.

Repack all road canisters every 3,000 miles. Part #005-10038 Repack all offroad canisters after every 10 hours of use. Part #005-10038MX

NEVER dyno test your bike with carbon ber or titanium canisters installed - the

intense heat and lack of cooling air can quickly burn through the canister material. Two Brothers Racing does not provide a warranty for burned canisters.

1997-2013 Kawasaki

KLR650

Slip-on V.A.L.E.™ Exhaust System with M-7 Canister Part # 005-630406V / 005-63407V

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